Catalyst layer-supporting substrate, method of producing the same and fuel cell

Abstract

A catalyst layer-supporting substrate includes a substrate and a catalyst layer. The catalyst layer includes a catalyst material and pores. The catalyst layer is formed on the substrate. The catalyst material has a layer or wire shape. A half-value width of a main peak of the catalyst material, as determined from X-ray diffraction spectrum of the catalyst layer, is 1.5° or more. A porosity of the catalyst layer is 30% or more.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2009-068659, filed Mar. 19, 2009, the entire contents of which are incorporated herein by reference.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The present invention relates to a catalyst layer-supporting substrate, a method of producing the catalyst layer-supporting substrate and a fuel cell.[0004]2. Description of the Related Art[0005]Polymer electrolyte fuel cells, in particular methanol-type polymer electrolyte fuel cells that use methanol solution as fuel and allow operation at low temperature and reduction in size and weight, have been studied eagerly as a power source of, for example, mobile devices. However, noble metal have been used as the main component of the catalyst materials for fuel cell electrodes, and thus, such electrodes are higher in cost and yet to be at the level allowing wide-spread use. ...

AI Technical Summary

Benefits of technology

The present invention provides a method for producing a catalyst layer-supporting substrate by forming layers of catalyst material and pore-forming material on a substrate. The catalyst material is deposited using sputtering or vapor deposition and has a layer or wire shape with a half-value width of 1.5° or more and a porosity of ≥30%. The substrate can be a fuel cell membrane. The technical effects include improved performance and durability of fuel cells.

Problems solved by technology

However, noble metal have been used as the main component of the catalyst materials for fuel cell electrodes, and thus, such electrodes are higher in cost and yet to be at the level allowing wide-spread use.

However, the method has a problem that the loss of the catalyst in the process is very large, approximately 30%.

However, when a catalyst layer is prepared by the method, fine particles of the catalyst material aggregate significantly, causing a problem of insufficient utilization efficiency of the catalyst material.

However, both of the catalyst layers are still unsatisfactory in utilization efficiency and durability of the catalyst material and demand further improvement.

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